Fixture for securing an electrical contact with a support shell



March 18, 1969 K. MCNAMARA Sheet FIXTURE FOR SECURING AN ELECTRICAL CONTACT WITH A SUPPORT SHELL Filed 00%- 28, 1966 INVENTOR K. M NAMARA ATTORNEY March 18, 196 K. McNAMARA 3,432,996

FIXTURE FOR SECURING AN ELECTRICAL CONTACT WITH A SUPPORT SHELL Filed Oct. 28. 1966 Sheet 0! 5 FIG.

March 18, 1969 K. MCNAMARA 3,432,906

FIXTURE FOR SECURING AN ELECTRICAL CONTACT WITH A SUPPORT SHELL Filed Oct. 28, 1966 Sheet 3 of s United States Patent 3,432,906 FIXTURE FOR SECURING AN ELECTRICAL CONTACT WITH A SUPPORT SHELL Kenneth McNamara, Fullerton, Md., assignor to Western Electric Company, Incorporated, New York, N.Y., a

corporation of New York Filed Oct. 28, 1966, Ser. No. 590,280

US. Cl. 29-203 12 Claims Int. Cl. B23 1 19/04 This invention relates to a fixture for securing an electrical contact to a supporting shell of a connector and relates more particularly to a fixture for bending an electrical contact about a nonconductive shell of a connector to facilitate the assembly and securing of the contact with the shell.

In the manufacture of plug-in type cords used in the communications industry, electrical contacts having retrofiexed ends are secured to a nonconductive shell with the retrofiexed ends inserted into spaced aligned apertures of the shell. Ferrule end portion of the contacts, which extend from the shell as a cantilever and to which associated tinsel conductors are secured, are retrofiexed about an end of the shell to effect assembling and securing of the contacts with the nonconductive shell.

In previous manual operations a relatively small portion of the shell was available for the operator to grip. The nonconductive shell had to be gripped about a relatively small end portion of the shell so that a substantial portion of the shell having the apertures formed therein and a portion of the shell which supports the secured contacts was exposed to facilitate the assembling and securing operation. In addition, each of the retrofiexed ends of the contacts had to be held manually tightly against one end of the apertures of the nonconductive shell when the contacts were being bent about the opposite end of the shell to preclude the possibility of the length of the portion of the contact between the retrofiexed ends thereof from being excessive during the assembling and securing operations and the contacts actually coming loose during subsequent use of the plug-in type cord. Because of the relatively small size of the contacts and the nonconductive shell, a dexterous operator was required to perform the tedious and time-consuming manual task of the assembly operation.

It is, therefore, an object of this invention to provide a new and improved fixture for assembling contacts with support shells.

Another object of this invention is to provide a new and improved fixture for holding electrical contacts in the desired positions in the apertures in the shell while the contacts are being bent about an end of the shell.

Still another object of this invention is to provide a new and improved fixture for forming successive bends in portions of contacts held against a shell to facilitate the retrofiexing ferrule portions of the contacts about an end of the shell.

A further object of this invention is to provide a new and improved fixture for holding electrical contacts with a shell and thereafter forming successive bends in portions of the contacts held with the shell to facilitate the securing of the contacts about an end of the shell and for clamping the unbent portions of the contacts during the forming of the bends to preclude buckling of the unbent portions thus providing a more uniform product having the desired mechanical and electrical characteristics A fixture illustrating certain features of the present invention may include means for supporting and holding a support with one end of the support extending as a cantilever from the means for supporting and holding the support. Retrofiexed ends of electrical contacts which are ice to be assembled with the support are inserted into apertures formed in the support and extend over an exposed surface of the support with ferrule portions of the opposite ends of the contacts extending as a cantilever from the cantilever portion of the support. Means are provided for holding each of the retrofiexed ends of the contacts against one end of an associated aperture of the support so that the retrofiexed ends of the contacts are held tightly during subsequent successive bending operations on the contacts to preclude undesirable outward movement of the retroflexed ends from within the associated apertures. Means are also provided for bending the ferrule portions of the contacts about One end of the support and into a position adjacent to the surface of the cantilever portion of the support on the opposite side from the exposed surface.

Other objects and features of the present invention will be more readily understood from the following detailed description of specific embodiments thereof when read in conjunction with the appended drawings, in which:

FIG. 1 is a perspective view showing a completely assembled plug-in type connector having contacts connected to conductors of a communications cord;

FIGS. 2 and 3 are perspective views showing opposite sides of a plastic shell which supports electrical contacts of a plug-in type cord;

FIGS. 4, 5 and 6 are perspective views showing various stages of assembly and bending of electrical contacts with the plastic shell illustrated in FIGS. 2 and 3;

FIG. 7 is a perspective view showing a fixture embodying certain principles of the invention;

FIG. 8 is a sectional view of the fixture taken along line 8-8 of FIG. 7 showing the plastic shell held in a nest of the fixture and also showing a bending member for engaging and bending contacts held with the shell;

FIGS. 9 and 10 are partial sectional views showing the relationship between the bending member and the contacts during various stages of the bending operation, and

FIG. 11 is a sectional view taken along line 1111 of FIG. 8 showing the details of bending surfaces of the bending member.

Referring now to the drawings and more particularly to FIG. 1 thereof, there is shown a plug-in type connector, designated generally by the reference numeral 21. The connector 21 is used for connecting a communications cord, designated generally by the reference numeral 24, to communications instruments (not shown). The connector 21 includes a nonconductive support shell, designated generally by the reference numeral 22, and a plurality of contacts, designated generally by the reference numeral 23, assembled therewith. Electrical conductors 2525 (FIGS. 4, 5 and 6) of the communications cord 24 are secured to the contacts 23-23 and a relief grommet 26, which is positioned over the cord, is keyed to an assembly which includes the shell 22 and a cover 27. A resilient locking tab 28, which facilitates the locking of the connector 21 within the communications instrument, is fastened to the shell 22 by a pair of rivets 2929 which extend through the shell and the cover 27 to hold the tab, shell and cover in the assembled relation with the relief grommet 26 secured therewith.

Referring now to FIGS. 2 through 6, the plastic support shell 22 is formed with a flat surface 31 on one side thereof and with an insulation bridge 32 formed transversely intermediate the ends thereof to preclude electrical contact between the locking tab 28 (FIG. 1) and the contacts 2323. The other side of the shell 22 is formed with a well 35 between spaced side walls 3333. The shell 22 is formed with a plurality of parallel spaced ribs 34-34 which extend longitudinally into the well 35 from an end 36 of the shell 22 to an intermediate portion thereof to provide a plurality of parallel spaced grooves 37-37 between the spaced ribs and between the side walls 33-33 and adjacent ribs.

The side walls 33-33 are formed with inwardly projecting extensions 38-38 to form a reduced portion of the well 35. A crimping bridge 39 is formed transversely in the reduced portion of the well 35 between the side wall extensions 38-38 and projects beyond the exposed surface of the side wall extensions and crimps the communications cord 24 against the inner surface of the cover 27 when the plug-in type connector 21 is assembled. The other end of the well 35 of the shell 22 is formed with a lead out support 41 for supporting the cord 24. In addition, slots 42-42 are formed in the well 35 adjacent to the support 41 for keying and locking flanged portions of the grommet 26 (FIG. 1) in the assembled connector 21.

A plurality of spaced transversely aligned apertures 43-43 are formed in the flat surface 31 of the shell 22 adjacent to one side of the bridge 32 and extend through the shell from the fiat surface to the well 35 between the side walls 33-33 with each of the apertures being in alignment with an associated one of the grooves 37-37. A pair of apertures 44-44 are formed in the shell 22 and extend from a surface 46 thereof, on the other side of the bridge 32, through the side wall extensions 38-38 to the other side of the shell adjacent to the projecting portion of the bridge 39.

Referring particularly to FIGS. 4 through 6, the insulated conductors 25-25 of the communications cord 24 (-FIG. 1) are secured fixedly to ferrule end portions 47-47 of the fiat electrical contacts 23-23. Each of the contacts 23-23 is also formed with a retroflexed end 48. In the manufacture of the plug-in type connector 21 (FIG. I), the contacts 23-23 are assembled with the shell 22 so that the contacts are supported by the shell. Initially, the retrofiexed end 48 of each of the contacts 23-23 is inserted into the associated aperture 43 and the contact is pulled so that the tip of the retroflexed end is positioned in engagement with a complementary beveled surface 49 formed along one end of each of the apertures 43-43, as shown in FIGS. 8 through 10. With the retroflexed end 48-48 of the contacts 23-23 held firmly within the associated apertures 43-43 of the shell 22, intermediate portions 50-50 of the contacts extend in spaced parallel alignment from the apertures to the end 36 of the shell and rest on the fiat surface 31 thereof. The ferrule end portions 47-47 of the contacts 23-23 extend in spaced parallel alignment as a cantilever from the end 36 of the shell 22 (FIG. 4).

It is noted that reference is made to the extension of the ferrule end portions 47-47 of the contacts 23-23 as a cantilever from the end 36 of the shell 22. It may be construed that the ferrule end portions 47-47 of the contacts 23-23 do not extend as a cantilever from the end of the shell 22 when the conductors 25-25 are preassembled with the ferrule end portions prior to the assembling and securing of the contacts with the shell. However, the invention is not limited to the assembly and securing of the contacts 23-23 with the shell 22 where the contacts have the conductors 25-25 preassembled therewith. Therefore, the ferrule end portions 47-47 of the contacts 23-23 will be considered to extend as a cantilever from the end 36 of the shell 22; but, it is to be understood that the invention relates to a fixture for securing contacts with a support regardless of whether conductors are preassembled with the contacts.

As shown in FIG. 5, a first 90 bend is formed in the ferrule end portions 47-47 of the contacts 23-23 about the end 36 of the' shell 22. As shown in FIG. 6, a second 90 bend is formed in the ferrule end portions 47-47 of the contacts 23-23 to move the ferrule end portions of the contacts into the associated grooves 37-37 of the shell 22. By forming two 90 bends in the contacts 23-23 around the end 36 of the shell 22, the contacts are bent about the end of the shell and are held securely to the shell by the locking action of the retroflexed ends 48-48 of the contacts within the associated apertures 43-43 of the shell and the portions of the contacts which are bent about the end of the shell.

Referring now to FIG. 7, there is shown a fixture, designated generally by the reference numeral 55, for bending, assembling and securing the contacts 23-23 with the shell 22, which includes a block 51 formed with a nest, designated generally by the reference numeral 52, along one upper end thereof. The nest 52 is formed between a pair of spaced parallel walls 53 and a rear Wall 54 and opens at one wall 56 of the block 51. A pair of aligning pins 57-57 are secured fixedly to a floor 58 of the nest 52 to facilitate the proper positioning of the apertures 44-44 of the shell 22 over the pins within the nest. The floor 58 of the nest 52 is formed with a transversely extending slot 59 (FIGS. 8, 9 and 10 for receiving the crimping bridge 39 of the shell 22 when the shell is positioned in the nest.

A slide, designated generally by the reference numeral 60, is mounted slidably in the block 51 between rearward extensions of the spaced parallel side walls 53-53. The slide 60 is formed with a longitudinal slot 61 and a handle '62 to facilitate manual movement of the slide. A headed screw 63 is positioned in the slot 61 of the slide 60 and is secured threadedly to the block 51 so that the slide is retained with the block but can be moved to position the forward end of the slide over a portion of the nest 52.

The wall 56 of the block 51 is provided with a transversely extending slot 64. A plurality of spring-biased clamping fingers, designated generally by the reference numeral 66, are positioned in and extend through a corresponding plurality of apertures 67-67 (FIGS. 8, 9 and 10) which extend from the upper surface of the slot 64 to the floor 58 of the nest 52. A lower portion of each of the fingers 66-66 is formed with an enlarged portion 68 (FIG. 8) having a shoulder 70 which engages a portion of the upper surface of the slot 64 to limit movement of the fingers upwardly through the associated apertures 67-67 by the action of a plurality of associated compression springs 69-69. A lower end of each of the compres sion springs 69-69 is positioned in an associated axial bore 71 (FIG. 8) formed in a plurality of adjustably positioned, threaded slugs 72-72. The upper ends of the compression springs 69-69 are positioned about reduced axial projections 73-73 on the lower ends of the fingers 66-66 to urge the fingers upwardly as viewed in FIGS. 7 through 10.

Each of the upper portions of the fingers 66-66 is formed with a beveled surface 74 complementary to the beveled surface 49 formed along one side of each of the apertures 43-43 of the shell 22 to facilitate the gripping of the tip of the retroflexed ends 48-48 of the contacts 23-23 (FIGS. 8, 9 and 10). Each of the upper ends of the fingers 66-66 are also formed with reduced portions 76 which project normally into the apertures 43-43 in the shell 22 to facilitate proper positioning of the shell in the nest 52 and further to ensure the gripping of the retroflexed ends 48-48 of the contacts 23-23 within the associated apertures during the bending operation. It is noted that the adjustable positioning of the slugs 72-72 within the block 51 varies the forces urging the fingers 66-66 within the associated apertures 67-67. It is further noted that if any of the ends 48-48 of the contacts 23-23 are not completely formed with the retroflexed end portions as viewed in FIGS. 4, 6, 8, 9 and 10, the beveled surfaces 74-74 of the associated fingers 66-66 could bend the ends sufficiently when the contact ends are inserted into the associated apertures 43-43 of the shell 22 to effect the assembly and securing of the contacts to the shell.

Referring further to FIG. 7, a bending member, designated generally by the reference numeral 77, is connected at opposite ends thereof to one end of a pair of spaced parallel linkage arms 78-78. The other ends of the linkage arms 78-78 are formed with longitudintal slots 79-79 (one shown) and are attached pivotally and slidably to the block 51 by a pair of headed pins 81-81 (one shown) which extend through the slots and are fixedly secured to the block. A pair of stop pins 82-82 (one shown) project transversely from opposite sides of and are secured fixedly to the block 51. The stop pins 82-82 project into the pivotal path of movement of the linkage arms 78-78 to limit downward movement of the bending member 77. It is noted, however, that the slots 79-79 in the linkage arms 78-78 facilitate linear movement of the bending member 77 even though the linkage arms are resting on the stop pins 82-82. A handle 83 extends upwardly from the bending member 77 to facilitate manual movement of the bending member.

As viewed in FIGS. 8 through 11, the bending member 77 includes a cross arm, designated generally by the reference numeral 84, which is secured at the opposite ends thereof to the spaced parallel linkage arms 78-78. The underside of the cross arm 84 is provided with a plurality of transversely extending, spaced, parallel grooves 86-86 which form a first bending surface of the bending member 77. A pedestal support, designated generally by the reference numeral 87, is positioned within a slot 88 formed in the upper surface of the cross arm 84. The pedestal support 87 is provided on the upper surface thereof With a plurality of spaced parallel pedestals 89-89 which form the second bending surface of the bending member 77 and which are aligned with the grooves 86-86 formed in the lower surface of the cross arm 84. The upper surface of each of the pedestals 89-89 is provided with a step 91.

A spacer 92 is positioned behind the steps 91 of the pedestals 89 and extends from the pedestal support 87 and beyond the stepped surface of the steps 91. A clamping plate, designated generally by the reference numeral 93,

is positioned in engagement with the spacer 92 and extends as a cantilever from the spacer over the pedestals 89-89 and the steps 91-91. The underside of the cantilever portion of the clamp 93 is formed with a plurality of spaced parallel ribs 94-94 which are aligned spatially above the centers of a corresponding plurality of grooves 96-96 formed by the spaces between the pedestals 89-89. The handle 83 is provided with a reduced shank 97 which is positioned through aligned apertures of the elements 84, 87, 92 and 93 of the bending member 77 and is threaded at the opposite end thereof to receive a fastener 98 for retaining the elements of the bending member in the assembly as shown in FIGS. 8 through 11.

Operation Referring to FIG. 8, the support shell 22 is positioned in the nest 52 of the block 51 so that the pins 57-57 are positioned in the apertures 44-44 of the shell. In addition, the crimping bridge 39 of the shell 22 is positioned within the slot 59 formed within the floor 58 of the nest 52. As the shell 22 is positioned properly within the nest 52, the apertures 43-43 of the shell are positioned over the reduced end portions 76-76 of the associated fingers 66-66. Since the compression springs 69-69 are urging the shoulders 70-70 of the enlarged portions 68-68 of the associated fingers 66-66 into abutting engagement with the upper surface of the slot 64, the reduced upper end portions 76 of the fingers are extended to the uppermost position where the beveled surfaces 49-49 of the apertures 43-43 are spaced from a portion of the beveled surfaces 74-74 of the associated fingers. When the plastic shell 22 is properly assembled in the nest 52 of the block 51, one end of the shell which includes the end 36 extends as a cantilever from the block.

After the plastic shell 22 has been positioned properly within the nest 52, the slide 60 is moved forward so that the leading edge of the slide projects over a small rearward portion of the surface 46 of the shell. The positioning of the slide 60 over the rearward portion of the shell 22 cooperates with the pins 57-57 and the slot 59 within the nest 52 to hold the shell in the position as viewed in FIGS. 8, 9 and 10 with a substantial portion of the flat surface 31 of the shell, including the apertures 43-43, being exposed. In addition, the positioning and clamping of the plastic shell 22 with one end of the shell extending as a cantilever facilitates freedom of movement of the bending member 77 during the bending operation so that the contacts 23-23 with the ferrule portions 47-47 can be easily assembled with and bent about the cantilever portion of the shell.

Subsequent to the assembly of the plastic shell 22 within the nest 52 of the block 51, the retroflexed ends 48-48 of the individual contacts 23-23 are pressed on top of the reduced portions 76-76 of the fingers 66-66 extending through the associated apertures 43-43 of the shell. As the retroflexed ends 48-48 of the individual contacts 23-23 are pressed on top of the reduced portions 76-76 of the fingers 66-66, the fingers are urged downwardly through the associated apertures 67-67 formed in the block 51 thereby providing sufiicient clearance for the retroflexed ends of the contacts to be inserted into the associated apertures of the shell. The contacts 23-23 are then pulled to the right, as viewed in FIG. 8, to position the top of the retroflexed ends tightly in engagement with the beveled surfaces 49-49 of the associated apertures 43-43.

As the tips of the retroflexed ends 48-48 of the contacts 23-23 are pulled tightly into engagement with the beveled surface 49 of the associated apertures 43-43, sufiicient clearance is provided within each of the apertures to facilitate upward movement of the reduced upper end portions 76-76 of the associated spring-biased fingers 66-66. As the biasing action of the compression springs 69-69 urges the associated fingers 66-66 upwardly, the tips of the retroflexed ends 48-48 of the contacts 23-23 are captured between the beveled surfaces 49-49 of the associated apertures 43-43 and the beveled surfaces 74-74. The reduced upper end portions 76-76 of the associated fingers 66-66 project into the associated apertures 43-43 of the shell 22 after the retroflexed ends 48-48 of the contacts 23-23 have been inserted into the associated apertures and lock tightly the retroflexed ends in the assembled position as shown in FIGS. 8, 9 and 10. Hence, while the tips of the retroflexed ends 48- 48 of the contacts 23-23 are captured between the beveled surfaces 49-49 of the apertures 43-43 and beveled surfaces 74-74 of the associated fingers 66-66, the reduced upper end portions 76-76 of the associated fingers hold the retroflexed ends of the contacts in the associated aperture to preclude undesirable movement of the retroflexed ends during the bending operations.

It is noted that when the fingers 66-66 are in a position to facilitate the gripping of the retroflexed ends 48-48 of the contacts 23-23, the abutting shoulders -70 of the enlarged portions 68-68 of the fingers are not in engagement with the upper surface of the slot 64 so that the gripping pressure applied to the retroflexed ends of the contacts is being supplied by the biasing force of the associated compression spring 69-69. It is further noted that the gripping of the retroflexed ends 48-48 of the contacts 23-23 from the underside of the plastic shell 22 eliminates the necessity for having overhead clamping elements for the contact during the initial bending operation. In addiiton, the absence of overhead clamping elements facilitates free access in the initial assembly of the retroflexed ends 48-48 of the contacts 23-23 with the shell 22. Further, if any of the ends 48-48 of the contacts 23-23 are not completely retroflexed, the ends could be formed by the upward movement of the beveled surfaces 74-74 of the associated spring-biased fingers 66-66 after the ends have been inserted into the associated apertures 43-43 of the shell 22.

Referring again to FIG. 8, as the retroflexed ends 48-48 of the contacts 23-23 are assembled and held 7 within the associated apertures 43-43 of the shell 22, the intermediate portions 50-50 of the contacts extend in parallel spaced alignment from the associated apertures over the fiat surface 31 of the shell and the ferrule end portions 47-47 of the contacts extend as a cantilever from the end 36 of the shell (FIG. 4).

Subsequent to the assembly of the retroflexed ends 48-48 of the contacts 23-23 within the associated apertures 43-43 of the shell 22, the bending member 77 is moved radially outwardly from the axis of the pins 81-81 so that the ends of the slots 79-79 which are furthest from the bending member strike the pins. Thereafter the bending member is pivoted downwardly from a position over the nested shell 22. Referring now to FIG. 9, as the bending member 77 is pivoted downwardly, the grooves 86-86 (FIG. 11) of the first bending surface engage and properly align the spaced parallel cantilever ferrule end portions 47-47 of the contacts 23-23. As the downward pivotal movement of the bending member 77 is continued, a 90 bend is formed in the contacts 23-23 about the end 36 of the shell 22 (FIG. Subsequently, the linkage arms 78-78 engage the associated stop pins 82-82 to preclude continued downward pivotal movement of the bending member 77. It is noted that the grooves 86-86 of the first bending surface of the bending member 77 facilitates the continued alignment of the spaced parallel contacts 23-23 during the forming of the first bend to maintain the contacts in a desirable array to preclude undesirable contacting of adjacent contacts.

Referring now to FIG. 10, subsequent to the forming of the first 90 bend in the ferrule end portions 47-47 of the contacts 23-23 and with the linkage arms 78-78 resting on the stop pins 82-82, the bending member is slid towards the block 51 along a linear path. The linear movement of the bending member 77 is facilitated by axial movement of the associated linkage arms 78-78 which is permitted by the pins 81-81 extending from opposite sides of the block 51 through the slots 79-7-9 in the arms. As the bending member 77 is moved along the linear path, the second bending surface of the bending member including the pedestals 89-89 engage the ferrule end portions 47-47 of the contacts 23-23 to form a second 90 bend in the contacts about the end 36 of the shell 22 so that the contacts are bent substantially 180 about the cantilever portion of the shell.

-As the bending member 77 is moved linearly towards the block 51, the grooves 96-96 formed between the spaced parallel pedestals 89-89 facilitate movement of the bending member along the spaced parallel ribs 34-34 which extend longitudinally into the well 35' of the shell 22. Further, as the bending member 77 approaches the rearwardmost position wherein the pins 81-81 are adjacent to the ends of the slots 79-79 of the associated linkage arms 78-78 closest to the bending member, the portion of the contacts 23-23 which has been bent about the end 36 of the shell 22 is bent additionally by engagement with the upper surfaces of the steps 91-91 and the portions of the lower surface of the clamp 93 aligned spatially above the steps.

As the second 90 bend is being formed, the lower surfaces of the clamp 93 extending between and adjacent to the ribs 94-94 engage the intermediate portions 50-50 of the contacts 23-23 adjacent to the end- 36 of the shell 22 and clamp the intermediate portions of the contacts against the flat surface 31 of the shell to preclude buckling of the intermediate portions of the contacts during the forming of the second bend. It is noted that if the clamp 93 was not utilized, the intermediate portions 50-50 of the contacts 23-23 might buckle during the forming of the second bend in the ferrule end portions 47-47 of the contacts thereby providing sufficient slack in the intermediate portions of the contacts to facilitate outward movement of the retrotlexed ends 48-48 of the contacts from within the associated apertures 43-43 of the shell after the shell is removed from the nest 52.

Thus, the embodiment of the fixture 55 facilitates a firm gripping of the shell 22 about a small portion of the shell so that those portions of the shell which receive the bent contacts 23-23 are easily accessible and sufficiently exposed to facilitate the assembly of the contacts with the shell. In addition, the features of the fixture 5, which facilitate the holding of the retroflexed ends 43-48 of the contacts 23-23 within the associated apertures 43-43 of the shell 22 during the forming operations do not require space which interfere with the forming operations. Further, the pivotal and linear movability of the bending member 77 facilitate a bending operation which permits the clamping of the intermediate portions -50 of the contacts 23-23 during the forming of the second bend in the ferrule end portions 47-47 of the contacts.

It is to be understood that the above-described arrangements are simply illustrative of the invention. Other arrangements may be devised by those skilled in the art which will embody the principles of the invention and fall within the spirit and scope thereof.

What is claimed is:

1. A fixture for assembling retroflexed bendable members on an apertured support, which comprises:

means for supporting and holding an apertured support with a substantial portion of one apertured surface of the support exposed and a free end of the support extending as a cantilever from the supporting and holding means,

means for holding a retroflexed end of each bendable member in an associated aperture in the exposed surface of the support with an intermediate portion of each member resting on the cantilever portion of the exposed surface of the support and the remaining portion of the member projecting beyond the cantilever portion of the support, and

means for bending the projecting portion of each member around the cantilever end of the support and into a position adjacent to the surface of the cantilever portion of the support opposite the exposed surface of the support so that each member is assembled with and secured to the support.

2. The fixture as set forth in claim 1, including means for holding a portion of each member resting on the exposed surface of the cantilever portion of the support in engagement with the support during the period when the projecting end portion of each member is being bent into a position adjacent to the other side of the support so that buckling of the portions of the member positioned on the exposed cantilever portion of the support is precluded when the end of the member is urged into the position adjacent to the other side of the support.

3. The fixture as set forth in claim '1 wherein the means for supporting and holding the shell include:

a block,

a nest formed in the block for receiving complementary one end of the support so that the opposite end of the support extends as a cantilever from the nest of the block, and

a slide supported movably on the block for overriding the end portion of the support which is positioned in the nest to hold the end portion of the support within the nest.

4. The fixture as set forth in claim 1 wherein the means for holding each of the retroflexed ends of the members in an associated aperture of the support includes:

a plurality of fingers extending into associated apertures of the support with the retrofiexed end of each associated member so that each of the associated fingers and retroflexed ends fill the associated aperture to hold the retroflexed end in assembly with the support within the associated aperture during the bending of the members.

5. The fixture as set forth in claim 4 wherein each of the fingers are biased individually into the associated aperatures of the support so that the associated retroflexed ends of the associated members are held individually independently of the remaining members.

6. The fixture as set forth in claim 1 wherein the means for bending the projecting portions of the bendable members includes:

a bending member positioned for pivotal and linear movement with respect to the means for supporting and holding the support,

a first bending surface formed on the bending member for aligning and bending the projecting portions of the ends of the bendable members so that when the bending member is pivoted from a position over the projecting portions of the bendable members and engages the projecting portions, continued pivotal movement of the bending member forms a first bend in the projecting portions of the bendable members to bend intermediate portions of the bendable members about the cantilever end of the support, and

a second bending surface formed on the bending member for engaging and bending the projecting portions of the bendable members after the first bend has been formed so that when the bending member is moved linearly under and adjacent to the cantilever portion of the support a second bend is formed in the projecting portions of the bendable members to 'bend the intermediate portions of the bendable members about the cantilever end of the support with the projecting portions of the bendable members moved into a position adjacent to the surface of the cantilever portion of the support which is on the side opposite from the exposed surface.

7. The fixture as set forth in claim 6 including means for limiting the downward pivotal movement of the bending member during the forming of the first bend in the intermediate portions of the bendable members and for positioning and supporting the bending member during the forming of the second bend in the intermediate portions of the bendable members.

8. The fixture as set forth in claim 6, wherein:

the first bending surface includes a plurality of spaced, parallel grooves formed in the bending member for facilitating aligning engagement with the projecting portions of the bendable members so that the 'bending of each bendable member is confined to the portion of the associated groove to maintain the bendable members in a desired alignment and array, and

the second bending surface includes a plurality of spaced, parallel pedestals for engaging the projecting portions of the spaced bendable members and bending the associated projecting portions into slots formed in the other side of the support positioned between parallel spaced ribs on the support with the spacing between the pedestals of the second bending surface receiving the spaced parallel ribs as the bending member is moved linearly under the cantilever end of the support.

9. The fixture as set forth in claim 1, including means for retroflexing a prebent end of each bendable member, said means having a portion associated with each aperture of the support into which the prebent end of the bendable member is inserted.

10. The fixture as set forth in claim 9 wherein the means for retroflexing the prebent ends of the bendable members includes:

a plurality of bending elements provided with portions projecting into associated apertures of the support, and

means for moving a bending surface of each of the bending elements into bending engagement with the prebent end of the associated bendable member inserted into the associated aperture of the support to retrofiex the prebent end of the bendable member.

11. A fixture for bending and assembling contacts with a support shell with the shell having spaced, aligned apertures formed therein and with each contact having a retroflexed end and a ferrule end portion, which comprises:

means for supporting and holding the shell with a sub- 5 stantial portion of one surface of the shell exposed and having apertures formed therein and a free end of the shell extending as a cantilever from the means for supporting and holding the shell,

means for holding each of the retroflexed ends of the contacts in an associated aperture of the shell with the portion of the contacts extending over the exposed surface of the cantilever portion of the shell and with the other ends of the contacts extending as a cantilever from the cantilever portion of the shell,

means for forming a first bend in the cantilever portion of the contacts so that intermediate portions of the contacts are bent partially around the cantilever end of the shell, and

means for forming a second bend in the bent cantilever portions of the contacts so that the intermediate poritons of the contacts are bent further around the cantilever end .of the shell and the cantilever portions of the contacts moved into a position adjacent to the opposite surface of the shell so that the contacts are assembled with and secured to the shell by the retroflexed ends of the contacts inserted within the apertures of the shell and the portion of the contacts bent about the cantilever end of the shell.

12. A fixture for bending and assembling contacts with a support shell having transversely aligned spaced apertures formed in an intermediate portion thereof and each of the contacts being provided with a retroflexed end and a ferrule end portion at opposite ends thereof, which comprises:

a support,

a nest formed in one surface along one edge of the support for supporting one end of the support shell therein with the other end of the shell extending as a cantilever from the nest,

a slide mounted movably on the support adjacent to the nest and movable to a position partially over the nest so that the slide overrides the end of the support shell positioned in the nest to hold the one end of the shell in the nest,

a plurality of spaced parallel fingers extending slidably into the nest and positioned to facilitate the insertion of the free end of each finger into an associated aperture of the shell when the shell is positioned in the nest, each of the fingers being biased individually independently of the remaining fingers into the nest, portions of the free ends of each of the fingers projecting into associated apertures of the shell with associated retroflexed ends of the contacts positioned in the associated apertures so that the free end portions of the fingers and the retorflexed ends of the contacts occupy the associated apertures to hold the retroflexed ends within the associated apertures during a bending of other portions of the contacts, the ferrule end portions of the contacts projecting from the cantilever end of the shell when the retroflexed ends of the contacts are inserted into the associated apertures of the shell,

a bending member, the bending member being provided with 'a first bending surface which engages the ferrule end portions of the contacts to form a first bend in intermediate portions of the contacts partially around the end of the cantilever portion of the shell, the bending member being formed with a second bending surface engageable with the ferrule end portions of the contacts for forming a second bend in the intermediate portions of the contacts around the end of the cantilever portion of the shell,

means for moving pivotally the bending member to move the first bending surface into aligning and bending engagement with the ferrule end portions of the contacts to form the first bend in the intermediate portions of the contacts and for moving linearly the bending member to move the second bending surface into bending engagement with the ferrule end portions of the contacts to form the second bend in the intermediate portions of the contacts,

means for limiting the pivotal movement of the bending member to effect the forming of the first bend in the intermediate portions of the contacts and for positioning and supporting the bending member during the linear movement of the bending member to effect the forming of the second bend in the intermediate portions of the contacts, and

means for clamping the portions of the contacts between the retroflexed ends and the intermediate portions thereof when the second bend is being formed in the intermediate portions of the contacts so that the contacts are held against and secured tightly to the shell.

References Cited UNITED STATES PATENTS 3,004,262 10/1961 Cubbidge et a1. 3,239,924 3/1966 Wagner. 3,267,716 8/1966 Hales 72384 3,344,499 10/ 1907 Cowsert.

THOMAS H. EAGER, Primary Examiner. 

1. A FIXTURE FOR ASSEMBLING RETROFLEXED BENDABLE MEMBERS ON AN APERTURED SUPPORT, WHICH COMPRISES: MEANS FOR SUPPORTING AND HOLDING AN APERTURED SUPPORT WITH A SUBSTANTIAL PORTION OF ONE APERTURED SURFACE OF THE SUPPORT EXPOSED AND A FREE END OF THE SUPPORT EXTENDING AS A CANTILEVER FROM THE SUPPORTING AND HOLDING MEANS, MEANS FOR HOLDING A RETROFLEXED END OF EACH BENDABLE MEMBER IN AN ASSOCIATED APERTURE IN THE EXPOSED SURFACE OF THE SUPPORT WITH AN INTERMEDIATE PORTION OF EACH MEMBER RESTING ON THE CANTILEVE PORTION OF THE EXPOSED SURFACE OF THE SUPPORT AND THE REMAINING PORTION OF THE MEMBER PROJECTING BEYOND THE CANTILEVER PORTION OF THE SUPPORT, AND MEANS FOR BENDING THE PROJECTING PORTION OF EACH MEMBER AROUND THE CANTILEVER END OF THE SUPPORT AND INTO A POSITION ADJACENT TO THE SURFACE OF THE CANTILEVER PORTION OF THE SUPPORT OPPOSITE THE EXPOSED SURFACE OF THE SUPPORT SO THAT EACH MEMBER IS ASSEMBLED WITH AND SECURED TO THE SUPPORT. 